An SBA 8(a) certified firm

DETAIL ENGINEERING DESIGN

Mechanical „ Structural „ Process „ Electrical Design Consulting
AutoCAD „ Inventor „ SolidWorks „ Microstation „ Intergraph PDS

113 Peterson Rd ▪ Knoxville, TN 37934

865.966.4402 ▪ 865.966.4584 (fax)
info@idi-tn.com
www.idi-tn.com
 NEW COKE FACILITY
Knoxville, Tennessee; Haverhill, Ohio; Brazil

Innovative Design provided engineering design and detail drafting services for new Coke Plants to be
constructed in America and in Brazil. IDI provided services on smaller task orders for mechanical,
structural, process and electrical design and detail drawings in English and Metric for overall plant design
and facility layout. IDI also provided conceptual design, layout of ovens, design of refractory structure, hot
duct, stacks, heat recovery steam generators, quench wharf & tower, conveyors, plant utilities,
foundations, catwalks, walkways, stairs, support platforms, structural supports, etc. After completion of
design drawing packages in English units, the new Brazil effort was then converted to metric units. A
Coke facility in Ohio was recently completed and is now fully operational. A facility in Brazil is currently
under construction.
 HIGH PRESSURE WASH PROCESS SKID
Maryville, Tennessee

Innovative Design provided services to engineer, design and detail a High Pressure Wash Process Skid
to be used on a gear parts inspection machine/conveyor unit for cleaning the parts and also to better
identify parts subject to failure. IDI teamed with a local fabricator to deliver a turn-key project. The project
was a success from start-up.
 NEW ALUMINUM CASTING LINE
Loudon, Tennessee

Innovative Design has performed many projects for this customer and is currently working on two
projects. Most recently, a preliminary concept and design was prepared for evaluating the cost of
installing a new aluminum casting process at an existing facility. IDI assisted the customer with budget
estimates for engineering, equipment, fabrication, etc. The Customer made the decision to install the
process and IDI was retained to prepare the detail design, including facility modifications, equipment,
hoods and ducts, recirculation process piping, troughs, furnace, catwalks, platforms, etc.
 TRUCK LOAD-OUT STATION
Loudon, Tennessee

Innovative Design, Inc. provided the engineering and design and design drawing package for a new Truck
Load-out Station to be constructed as an addition to an existing Rail Load-Out Station. The Structural
Engineering and design included the additional load-out structure including foundations, platform, stairs,
two swing-down platforms and fall protection.
 MECHANICAL/MACHINE DESIGN
JAW CRUSHER
Greenville, Tennessee

Innovative Design has provided engineering and design services for various mechanical,
structural and electrical projects. IDI is also providing multi-discipline services for a plant/process
expansion for this fused-silica manufacturer. Services include mechanical, process, structural,
and electrical engineering, as well as 3D design and detailing using SolidWorks and Inventor.
 BEAMLINE 17 - SEQUOIA ENCLOSURE
Oak Ridge, Tennessee

Innovative Design, Inc. was chosen by the Instruments Division at the Spallation Neutron Source in Oak
Ridge to engineer and design an extremely large and geometrically challenging detector vessel and
instruments concrete enclosure structure. The scope of work included structural engineering and design,
electrical engineering, HVAC and fire protection and a complete set of design drawings in ProE and
AutoCAD.

The concrete enclosure structure has complex geometry in three dimensions with numerous openings,
cut-outs, doors, hatches and roof elements that are structurally integrated but removable. The geometry
of the enclosure had to conform to the geometry of the equipment to provide the necessary radiation
shielding around the equipment and to avoid radiation shine paths. This structure was designed for dead,
collateral (other dead load to account for conduit, wiring, lights, etc), live and seismic loadings under PC-3
performance classification.
 PROCESS PIPING, VESSELS, HEAT EXCHANGERS, REVERSE OSMOSIS,
WATER PURIFICATION PROJECTS

IDI provided detail engineering design including 3D CAD design for the fabrication and assembly of a
variety of projects over the past several years. Projects required the understanding of ASME Section VIII,
TEMA, AWS and welding of high alloy materials, testing, quality, and manufacturing/fabrication
processes. The wide variety of projects included Pressure Vessels, Heat Exchangers, Evaporaters, Brine
Concentrators, Distillate Tanks, Feed Heaters, Flash Tanks, etc. Many systems were skid mounted
complete systems where complicated design of pipe routing was accomplished and interconnect design
issues were incorporated for installation after shipping at customer facility or site. Some of these systems
were smaller pharmaceutical units and many were extremely large plant scale projects. The smaller
projects were often more of a design challenge than the larger ones.
 NEW PIPE BRIDGE AND TOWER
Loudon, Tennessee

IDI was chosen by this Customer to design a large pipe bridge and tower to support approximately 13
pipe services from a new process plant on the adjacent property to tie in to the new facility in Loudon. IDI
engineered, designed and detailed the structures including foundation. Preliminary site layouts and
conceptual design was performed at the start to obtain customer feedback necessary for the decision of
location of the structure. A complete set of detail design drawings were then produced by IDI for
fabrication and erection.
 CRYOGENICS – COLD SOURCE PROJECT
Oak Ridge National Laboratory, Oak Ridge, Tennessee

In the Fall of 2005, and after performing many small task orders previously, IDI was invited to provide
qualified resources on an urgent high-profile/accelerated schedule project for the High Flux Isotope
Reactor at Oak Ridge National Laboratory. The engineering professionals provided by IDI included pipe
stress engineers, structural engineers, and mechanical/piping designers. IDI offered an “innovative”
approach to the required process design. Most of the critical vessels and piping systems were to be
located in a very small existing facility. This resulted in an extraordinary maze of piping, equipment,
supports, cranes, and electrical systems. By offering the use of a 3d modeling software, our experienced
design staff located interferences and maximized accuracy. Many additional tasks, such as the
generation of piping spools, isometrics, bills of materials, etc. were automatically generated within the
program, thereby minimizing costs. The Customer was in full agreement with IDI’s design and has been
extremely pleased with the results-to-date.
 REACTOR TOOLS FINITE ELEMENT ANALYSIS – COLD SOURCE PROJECT
Oak Ridge National Laboratory, Oak Ridge, Tennessee

After over 30 years of use, it was found by the Department of Energy that certain reactor tools needed to
be evaluated for strength/failure before approval for continued use at the Reactor. IDI was chosen to
prepare engineering studies and structural analysis on 6 of 11 tools. IDI will evaluate the remaining 5
tools later this year. IDI was aware that Merrick and Company had resources that were very
knowledgeable in performing such types of calculations and therefore subcontracted to Merrick for this
expertise. Because the decision to have the tools analyzed was reached by ORNL late in 2005, the
project was accelerated and a quick turn-around for deliverables was requested. Merrick went the extra
length to accommodate IDI and the customer and nearly impossible deliverables/schedules were met
within budget. It was found that within certain code criteria, several of these tools did indeed fail per
analysis. Innovative Design and Merrick & Company began an ongoing relationship with this project.
 PLANT/PROCESS EXPANSION
Greenville, Tennessee

After performing successfully on smaller design projects, the Customer invited Innovative Design, Inc. to
provide engineering and design services for a plant/process expansion for this Fused Silica manufacturer.
IDI provided conceptual 3D models and layouts in SolidWorks to aid in management decisions and
engineering decisions. After a concept was chosen, IDI engineered and designed the processes which
included breaker tables, ingot cradles, grizzles, bucket elevators, conveyors, tabor screen, jaw crusher,
dust collection, chutes, etc. Engineering functions included specifying equipment, sizing Dedust, and
Structural engineering for the design of foundations and heavy support structures capable of handling
heavy and vibrating loads.
 FEASIBILITY STUDY – REACTOR POOL COOLANT WATER STORAGE TANK RELOCATION
Oak Ridge National Laboratory, Oak Ridge, Tennessee

IDI provided a detailed engineering report and feasibility study to install a new reactor pool coolant water
storage tank outside the reactor building. The study considered two possible locations, one of which was
to fill and occupy space on top of an old underground storage tank. This design involved filling the tank
with concrete, which also required a study of soil capacity. A detailed and thorough cost estimate was
prepared for both options. Design drawings were created for the chosen option.

HFIR Pool Water Storage Tank Cost Estimate

Major Item Material Installation Sub-total Notes

Fill Existing Underground Tank $26,000 $24,000 $50,000

Storage Tanks - 2 $600,000 $300,000 $900,000 14' Dia x 34 ft - Double Wall - 316L SS

Line - 4 contollers @ $226 ea, 4x200 ft tracing @ $4/ft; Tank - 2

controllers @ $226 ea/tank, 2 x 200 ft tracing @$6/ft/tank
Heat Tracing $11,000 $20,000 $31,000

Insulation $100,000 Fiberglass - 1" with SS Jacket

Double Wall (6"- 316L Sched 40 inner, 10" - 304L Sched 10

Piping - Double Wall $95,000 $150,000 $245,000 Outer) - 400 ft

Valves - 6" $7,500 $7,500 $15,000 Socket Weld, mounted to 10" flanges

Piping - Overflow & Vent $20,000 $25,000 $45,000 Schedule 10 - 6"

Line - 10 sensors (connect 2 20' sections of line together) @

$250 each; Tank - interstitial capacitance monitor - $2500 ea;
Leak Detection $35,000 $50,000 $85,000 Alarm Panel $5000

Level Guages/Alarms $12,500 $15,000 $27,500 13'10" Long Kobold Tank Guages w/Tranmitters - $6,200 ea

Detail Engineering - 10% $149,850 $149,850

Miscellaneous pipe, valves, pipe supports, electrical,

Contingency - 15% $247,253 transportation/shipping, hydrostatic testing

Total Estimate $1,895,603

 RELOCATION OPTION STUDY - BUILDINGS 3025E AND 3525
MELTON VALLEY NUCLEAR FACILITY COMPLEX
OAK RIDGE NATIONAL LABORATORY
Oak Ridge, Tennessee

Innovative Design, Inc. and Merrick & Company performed together on this project to provide the ORNL
management team on the Nuclear Facility Consolidation Project a 6-option study to evaluate the feasibility
of relocating two nuclear facilities from the Bethel Valley campus to the nuclear campus of Melton Valley.
The options evaluated included utilizing existing hot cell space in existing facilities, the addition of
annexes, and a greenfield facility, which would also include a waste treatment option. Drawings of existing
and new facilities were created, cost estimates for all six options were created, and a qualitative risk
analysis of risk was performed.
 CRANE LOAD TEST (DEADMAN LIFT) PROJECT
Beaufort, South Carolina

Innovative Design, Inc. was chosen to engineer and design a crane lift test structure to be installed in a
remote location at the Marine Corp Air Station parking lot for load testing a crane routinely utilized for
lifting military aircraft. Included in the scope was a preliminary engineering report and budget estimate for
contracting the construction and fabrication. A detailed design was provided as well.
 ONGOING-CONCRETE PLANT ENGINEERING & DESIGN
Atlanta, Georgia

Innovative Design has been providing engineering, design and drafting services both on-site and off-site
for this Customer for approximately 3 years. Engineering functions have included sizing and specifying
equipment, working with vendors, preparing bid packages and data sheets, specifying and sizing Dedust
lines, performing load calculations for Chutes, Dedust, Expansion Joints and large equipment for both
Wet Grinding and Dry Grinding operations. Design and drafting has included general arrangement
drawings, layouts, concepts, equipment drawings, (English and Metric), and detail services. IDI was
contracted to perform engineering, design and detailing for large packages of Chutes and Dedust for a
large cement plant project in Texas. Work is ongoing.